Method for manufacturing a handle for a personal care implement

Abstract

A method for manufacturing a handle for a personal care implement includes molding from a fiber-reinforced material, preferably by injection-molding, a core-connector unit having a core structure and a connector for attaching and detaching a head to and from the handle, and molding, preferably by injection-molding, a polymeric material onto the core structure to form a component that at last partially covers the core structure.

What is claimed is: 
     
       1. A method for manufacturing a handle ( 12 ) for a personal care implement ( 10 ), the method comprising steps of:
 molding a core-connector unit ( 20 ) from a fiber-reinforced material, the core-connector unit ( 20 ) comprising a core structure ( 18 ) and a connector ( 16 ) for attaching and detaching a head ( 14 ) to and from the handle ( 12 ),
 wherein the connector ( 16 ) and the core structure ( 18 ) are made as one unitary piece, 
 wherein the connector ( 16 ) of the core-connector unit ( 20 ) is molded to have a cavity ( 52 ), and 
 
 molding a polymeric material onto the core structure ( 18 ) to form a second component ( 22 ), the second component ( 22 ) at last partially covering the core structure ( 18 ),
 wherein the core-connector unit ( 20 ) together with the second component ( 22 ) define an overall length extension ( 28 ) of the handle ( 12 ), the overall length extension ( 28 ) extending from a proximal end ( 30 ) closest to the head ( 14 ) to a distal end ( 32 ), the distal end ( 32 ) being opposite the proximal end ( 30 ), and 
 wherein the core structure ( 18 ) extends at least 75% along the overall length extension ( 28 ) of the handle ( 12 ). 
 
 
     
     
       2. The method of  claim 1 , further comprising a step of molding a third component onto at least one of the core structure ( 18 ) and the second component ( 22 ), the third component at least partially covering the at least one of the core structure ( 18 ) and the second component ( 22 ) to form a gripping area ( 44 ) of the handle ( 12 ). 
     
     
       3. The method of  claim 2 , wherein the third component is made from at least one of a thermoplastic elastomer material and a polypropylene material. 
     
     
       4. The method of  claim 2 , wherein the step of molding the third component comprises injection molding. 
     
     
       5. The method of  claim 1 , further comprising a step of inserting a snap-fit element ( 26 ) into the cavity ( 52 ) provided in the connector ( 16 ). 
     
     
       6. The method of  claim 5 , wherein the snap-fit element ( 26 ) is a spring-loaded ball element. 
     
     
       7. The method of  claim 6 , further comprising a step of inserting a spring ( 54 ), a ball ( 56 ), and a cap ( 58 ) into the cavity ( 52 ) of the connector ( 16 ), the cap ( 58 ) holding the compressed spring ( 54 ) and the ball ( 56 ) in place. 
     
     
       8. The method of  claim 7 , wherein the cap ( 58 ) is fixed in the cavity  52  by at least one of press-fitting and ultrasonic welding. 
     
     
       9. The method of  claim 7 , wherein the cap ( 58 ) is made from a fiber-reinforced material or metal. 
     
     
       10. The method of  claim 6 , wherein the spring ( 54 ) is made from stainless steel. 
     
     
       11. The method of  claim 1 , wherein the fiber-reinforced material is a composite material comprising a polymer base material. 
     
     
       12. The method of  claim 11 , wherein the polymer base material is selected from the group consisting of polyamide, styrene acrylonitrile resin, polybutylene terephthalate, polyethylene terephthalate, recycled plastic materials, and any combination thereof. 
     
     
       13. The method of  claim 1 , wherein the fiber-reinforced material comprises from about 10 wt % to about 50 wt % of fiber selected from the group consisting of glass fibers, carbon fibers, aramid fibers, basalt fibers, wood fibers, and any combination thereof. 
     
     
       14. The method of  claim 1 , wherein the polymeric material forming the second component ( 22 ) comprises a polymer base material and an inorganic filler material, wherein the polymer base material is selected from the group consisting of polyamide, styrene acrylonitrile resin, polybutylene terephthalate, polyethylene terephthalate, recycled plastic materials, and any combination thereof. 
     
     
       15. The method of  claim 14 , wherein the filler material is selected from the group consisting of zinc oxide, iron oxide, barium sulfate, titanium dioxide, aluminum oxide and any combinations thereof, wherein the filler material comprises from about 50 wt % to about 80 wt % of the polymeric material. 
     
     
       16. The method of  claim 1 , wherein the step of molding a core-connector unit ( 20 ) comprises injection molding. 
     
     
       17. The method of  claim 1 , wherein the step of molding a polymeric material comprises injection molding.